Positioning:
The Ford Sierra was a pivotal model for Ford of Europe, designed to bridge the gap between traditional saloons and hatchbacks, offering a blend of practicality, comfort, and European driving dynamics. It aimed to compete in the highly competitive mid-size family car segment.
Competitors:
Key competitors included the Volkswagen Passat, Opel/Vauxhall Vectra, Peugeot 405, Renault 21, and Fiat Croma.
Aerodynamics:
The Sierra was noted for its advanced (for the time) aerodynamic 'jelly mould' styling, contributing to improved fuel efficiency and reduced wind noise. This design language influenced subsequent Ford models.
Powertrain Options:
Offered a wide range of engines from economical 1.3L to more powerful 2.0L and performance variants like the Cosworth models.
Years Covered:
1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993
Regions Covered:
Primarily European markets, but applicable to global variations where specifications align.
Estimated Page Count:
Over 1000 pages (typical for comprehensive workshop manuals of this era)
Type:
Workshop Service Repair Manual
Powertrain:
Engine mechanical, fuel system (carburetor and injection), ignition system, exhaust system, transmission (manual and automatic), drivetrain, differentials.
Chassis:
Suspension (front and rear), steering system, brakes (front and rear disc/drum), wheels, tires.
Electrical:
Battery, charging system, starting system, lighting, instrumentation, engine control unit (ECU), body control module (BCM), wiring diagrams for all major systems.
Body And Interior:
Body construction, exterior panels, doors, glass, interior trim, seating, HVAC system, body sealing.
Heating And Ventilation:
Covers HVAC system components, blower motor, heater core, A/C system (if fitted), and ventilation ducting.
Instrumentation And Gauges:
Details on the instrument cluster, speedometer, tachometer, warning lights, and their associated sensors and wiring.
Maintenance:
Routine checks, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug replacement, belt tensioning.
Repair:
Engine overhaul, cylinder head removal/installation, carburetor/injector servicing, transmission overhaul and repair, brake component replacement, suspension component replacement, electrical component diagnosis and repair.
Troubleshooting:
Diagnostic flowcharts for common drivability issues, electrical faults, and mechanical problems.
Specifications And Data:
Torque specifications, clearances, measurements, wiring diagrams, component identification.
Bodywork Repair:
Includes procedures for panel removal/installation, dent repair, welding, and rust prevention/repair.
Fuel System Diagnosis:
Troubleshooting for carbureted and fuel-injected systems, including fuel pump testing, injector diagnosis, and idle speed control.
Emission Controls:
Details on emission control systems relevant to the era, including catalytic converters and exhaust gas recirculation (EGR) systems where applicable.
Timing Belt Replacement:
Critical procedure for CVH and DOHC engines, including correct timing marks and tensioning.
Depth:
Comprehensive from basic maintenance to major component overhaul and diagnostics. Includes detailed procedures, specifications, and troubleshooting guides suitable for professional mechanics and advanced DIY enthusiasts.
Diagnostic Tools:
Outlines basic diagnostic procedures using hand tools and multimeters. References to early Ford diagnostic equipment may be present.
Engine Family:
Ford Pinto (OHC), Ford CVH, Ford Cologne V6
Displacement And Power:
Common variants include: 1.3L (OHC, ~60-66 hp), 1.6L (OHC/CVH, ~75-90 hp), 1.8L (CVH/DOHC, ~90-115 hp), 2.0L (OHC/DOHC, ~105-130 hp), 2.3L Diesel (~67 hp), 2.8L Cologne V6 (~130-150 hp), 2.9L Cologne V6 (~140-145 hp), 2.0L DOHC Cosworth YB Turbo (~204 hp).
Torque Figures:
Torque figures varied significantly by engine. For example, the 2.0 DOHC might produce around 170 Nm (125 lb-ft), while the 2.0 Cosworth YB Turbo could exceed 280 Nm (207 lb-ft).
Fuel Delivery:
Carburetor (e.g., Weber, Motorcraft) for earlier/lower-spec models, Electronic Fuel Injection (EFI) for later/higher-spec models and performance variants.
Ignition Type:
Distributor-based ignition for early models, Electronic Ignition (EI) and later distributorless ignition systems (DIS) for certain variants.
Coolant Type:
Ethylene glycol-based antifreeze (typically a 50/50 mix with distilled water). Specific Ford coolant recommendations may apply.
Transmission Type:
Four-speed manual transmission (early models), Five-speed manual transmission (later models and performance variants).
Transmission Type:
Three-speed automatic transmission (e.g., C3), Four-speed automatic transmission (e.g., A4LD).
Drive Layout:
Rear-wheel drive (RWD) standard. Select models offered four-wheel drive (4WD) with transfer case.
Manual Transmission Fluid:
API GL-4 or GL-5 gear oil, typically SAE 75W-90 or 80W-90. Refer to specific manual for exact specification.
Automatic Transmission Fluid:
Mercon or equivalent ATF fluid (check specific transmission application in manual).
Wheelbase:
Approximately 2600 mm (102.4 inches) for most models.
Length:
Varies by body style (Hatchback, Sedan, Wagon, Van). Example: Hatchback ~4350 mm (171.3 inches).
Width:
Approximately 1700 mm (66.9 inches).
Curb Weight:
Ranges from approximately 1050 kg to 1400 kg depending on engine and body style.
Gross Vehicle Weight Rating:
Typically around 1700-1900 kg.
Cargo Volume:
Varies by body style. Hatchback offers significant cargo space with rear seats folded.
Crash Test Performance:
As a vehicle from the early to mid-1980s, Euro NCAP and NHTSA testing standards were less stringent. The Sierra met the safety standards of its time, incorporating features like padded dashboards and safety belts. Specific numerical ratings are not directly comparable to modern standards.
Braking System:
Front disc brakes, rear drum brakes on most models. Higher performance variants often featured four-wheel disc brakes.
Suspension Design:
Independent front suspension (MacPherson struts), Watt's linkage rear suspension (on RWD models) provided good handling characteristics for its era.
Seat Belts:
Three-point front seat belts, lap belts in the rear (may have gained three-point rear belts in later years/higher trims).
Interior Safety:
Energy-absorbing steering column, padded interior surfaces, safety glass.
Oil Change Interval:
Typically every 10,000 km (6,000 miles) or 12 months, whichever comes first. May vary based on engine oil type and driving conditions.
Air Filter Replacement:
Recommended every 20,000 km (12,000 miles) or annually.
Spark Plug Replacement:
Varies by spark plug type. Platinum plugs might extend to 50,000-100,000 km, while standard plugs could be 20,000-30,000 km.
Coolant Change Interval:
Typically every 2-3 years or 40,000-60,000 km.
Engine Oil Viscosity:
Common recommendations include 10W-40, 15W-40, or 5W-30 depending on temperature and engine type. Refer to the manual for precise specifications and API service classifications.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Rust And Corrosion:
Common issue for vehicles of this age, particularly around wheel arches, sills, and suspension mounting points. Regular inspection and preventative treatment are crucial.
Electrical Gremlins:
Wiring loom degradation, corroded connectors, and faulty relays can lead to intermittent electrical problems, especially in older vehicles.
Cvh Engine Specifics:
Some CVH engines could be prone to head gasket issues if not properly maintained, particularly overheating. Timing belt maintenance is critical.
Suspension Wear:
Worn bushes, ball joints, and shock absorbers are common wear items that can affect handling and ride quality.
Common Parts:
Many common service parts are still available from specialist suppliers, but some trim pieces or less common components may be scarce.
Ford Of Europe:
The Ford Sierra was developed by Ford of Europe as a successor to the Ford Taunus/Cortina range. It represented a significant step forward in design and technology for Ford's European operations.
Facelifts And Updates:
Received a significant facelift in 1987, introducing a more rounded front end (often referred to as the 'Sierra RS' or 'Facelift' model), updated interior, and improved chassis components. The original 'jelly mould' styling was initially controversial but became iconic.
Production Period:
Produced from 1982 to 1993.
Manufacturing Locations:
Major production facilities were located in Germany (Cologne), Belgium (Genk), and the United Kingdom (Dagenham).
Notable Variants:
Including the performance-oriented XR4, XR4i, XR4x4, and the legendary Sierra RS Cosworth and RS500 Cosworth models, which achieved significant success in motorsport, particularly rallying and touring car racing.
